Reusable and recyclable packaging for shock and static sensitive objects

ABSTRACT

The invention provides a dissembleable and reusable package is provided for static, debris and shock sensitive objects. The package comprises a folding box of single piece static dissipative corrugated plastic interlocking configuration. The box has an interlocking bottom, an open top and two pairs of parallel opposite sides. A shock absorbing pad structure fits against the central portions of the sides. The pad structure is a solid self-skinning plastic foam which is static dissipative. It is detachably attachable against the sides utilizing fasteners. A shock absorbing plastic bottom pad fits inside of the box atop its bottom. An open top static dissipative plastic bag fits within the box atop the shock absorbing bottom pad and substantially lines the box. A sensitive object holding structure includes first and second pluralities of static dissipative corrugated plastic walls which interlock with one another, the pluralities of walls being mutually perpendicular. The walls are releasably interlockable with one another and, when interlocked, define a plurality of cavities, each of which is adapted to closely hold one of the sensitive objects. The sensitive object holding structure is of a size to fit within the bag and, when the bag is pushed within the box, is of a size such that the respective opposite ends of the walls are closely adjacent the interiors of the sides of the box.

DESCRIPTION

1. Technical Field

The present invention relates to the packaging art, more particularly tothe art of packaging shock sensitive objects which are also sensitive tostatic electricity. More specifically still, the invention is related toreusable and recyclable packaging for electronic components such as discdrives.

2. Background of the Invention

Electronic components, such as disc drives, are sensitive to shock,static charges and particulate matter such as dust. In the past this hasoften required individual plastic bagging of the components to protectthem from debris and from static along with the packaging of the baggedcomponent in a shock absorbing plastic foam. When multiple packaging ofcomponents has been utilized the boxes which have formed the packageshave generally been glued together and/or have utilized glue to attachshock absorbing padding and the like. Generally the packaging has beenthrown away after a single use. The cost of such waste is staggering.The environmental impact is even worse.

The present invention is directed to overcoming one or more of theproblems as set forth above.

DISCLOSURE OF INVENTION

In accordance with an embodiment of the present invention adissembleable and reusable package is provided for static, debris andshock sensitive objects. The package comprises a folding box of singlepiece interlocking configuration which is made of static dissipativecorrugated plastic. The box has an interlocking bottom, an open top andtwo pairs of parallel opposite sides having respective upper, centraland lower portions. A shock absorbing pad structure is provided whichfits against the respective central portions of the sides. The padstructure is made of a plastic foam covered with a plastic staticdissipative skin. The pad structure is detachably attachable utilizingfasteners against the respective portions of the sides. A shockabsorbing plastic bottom pad fits inside of the box atop its bottom. Anopen top bag is made of static dissipative plastic film and is adaptedto fit within the box atop the shock absorbing bottom pad and tosubstantially line the box. A sensitive object holding structureincludes first and second pluralities of static dissipative corrugatedplastic walls which interlock with one another, the pluralities of wallsbeing mutually perpendicular. The walls are releasably interlockablewith one another and, when interlocked, define a plurality of cavities,each of which is adapted to closely hold one of the sensitive objects.The sensitive object holding structure is of a size to fit within thebag and, when the bag is pushed within the box, is of a size such thatthe respective opposite ends of the walls are closely adjacent theinteriors of the sides of the box.

A package as described above has a number of advantages over the priorart as discussed above. Because the parts are dissembleable the packagecan be readily broken down and the individual parts can be readily andinexpensively shipped back from the recipient to the sender for reuse.Because the parts are all of plastic they are generally tough enough soas to be reusable many times before replacement. Since no glue isutilized to hold any of the parts together it is not necessary tosomehow dissolve away the glue in order to collapse the structure.Insofar as recycling is concerned the plastic corrugated can be groundup and the plastic film of the bag and the foam pieces can be ground upfor insulation and carpet mats and the like. The resulting cost savingsare obvious. And, such reuse and recycling is clearly advantageous tothe environment. Furthermore, the packages can be readily attached to aconventional shipping pad and transported using lift trucks and thelike. Use of a pad structure which is of a solid plastic foam coveredwith a plastic static dissipative skin is particularly advantageous inthat it provides shock resistance, static dissipative properties andprotection from debris should any of the foam deteriorate.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood by reference to the figures ofthe drawings wherein like numbers denote like parts throughout andwherein:

FIG. 1 illustrates, in top corner perspective, partially cut away, apackage in accordance with an embodiment of the present invention;

FIG. 2 illustrates, in top corner perspective and exploded view of theembodiment of FIG. 1;

FIG. 3 illustrates, in partial side sectional view, a detail in theembodiment of FIGS. 1 and 2;

FIG. 4 illustrates, in plan view, a folded flat embodiment of the boxportion of the embodiment of FIG. 1;

FIG. 5 illustrates, in bottom corner perspective view, the assembled boxportion of the embodiment of FIGS. 1 and 2;

FIG. 6 illustrates, in top corner exploded view, details in the assemblysensitive objects holding structure of the embodiment of FIGS. 1 and 2;and

FIG. 7 illustrates, in top corner perspective view, a plurality ofpackages in accordance with the present invention attached to aconventional shipping pad.

BEST MODE FOR CARRYING OUT INVENTION

Adverting to the figures of the drawings, and first primarily to FIGS. 1and 2, there is illustrated a disassembleable and reusable package 10 inaccordance with an embodiment of the present invention. The packaging 10can be used for packaging static, debris and shock sensitive objects.The package 10 includes a folding box 12 which is of single pieceinterlocking configuration and is made of static dissipative corrugatedplastic. The box 12 (see FIGS. 4 and 5) has an interlocking bottom 14formed by interlocking tabs 16,18,20 and 22. The box also has an opentop 24 (FIG. 2) and two pairs 26,28 of parallel opposite sides. Thepairs 26,28 of opposite sides have (see FIGS. 4 and 5) respective upper30, central 32 and lower 34 portions.

In the particular embodiment illustrated the central portions 32 of thepairs 26,28 of opposite sides have holes 36 therethrough for reasonswhich will be described shortly.

A shock absorbing pad structure 38, seen in FIGS. 1, 2 and 3, is adaptedto fit against the respective central portions 32 of the pairs 26,28 ofparallel opposite sides of the folding box 12. As is seen in FIG. 3 thepad structure 38 is made of a solid plastic foam material 40 coveredwith a plastic static dissipative skin 42. The entire pad structure 38ids manufactured in a single operation and is generally about 1/16thinch thick. The shock absorbing pad structure 38, in the embodimentillustrated, includes (see FIG. 2) a pair of arms 44,46 hinged togetherby the plastic skin 42 at hinge region 48 whereby each of the padstructures 38 can be folded flat for storage and/or shipment. Each ofthe pad structures 38 includes a plurality of holes 50 through itadapted to be aligned with the holes 36 in the respective of the twopairs 26,28 of parallel opposite sides of the folding box 12.

As shown in FIGS. 1-3 fasteners 52 are provided for detachably attachingthe pad structures 38 against the respective central portions 32 of thepairs 26,28 of parallel opposite sides of the folding box 12. In theparticular embodiment illustrated the fasteners 52 include a first orouter member 54 and a second or inner member 56 which interlock with oneanother as seen most clearly in FIG. 3. The fasteners 52 fit within theholes 36 and 50 and fasten to one another thereby holding the shockabsorbing pad structure 38 against the folding box 12. The fasteners 52can readily detach whereby the pad structures 38 can be disengaged fromthe folding box 12 for shipment back to the manufacturer and reuse.

As may be seen in FIGS. 1 and 2 a shock absorbing plastic bottom pad 58is provided to absorb shocks upon the bottom of the reusable package 10.The bottom pad 58 is adapted to fit within the folding box 12 and to sitinside of the box 12 atop its interlocking bottom 14. The staticdissipative plastic sheet 60 fits within the folding box 12 and isadapted to sit above the bottom pad 58. The static dissipative plasticsheet serves not only to keep static charges away from the objects orcomponents within the package 10, but also to keep debris from thebottom pad 58 from reaching the components stored within the folding box12.

Bag 62, made of static dissipative plastic, is adapted to fit within thebox 12 atop the shock absorbing bottom pad 58, and, when such ispresent, above the static dissipative plastic sheet 60, as well. The bag62 serves to substantially line the box 12 and to hold within it asensitive object holding structure 54 which will be described infollowing.

The sensitive object holding structure 54 is seen in FIGS. 1, 2 and 6.It includes a first plurality 66 of static dissipative corrugatedplastic parallel wall 68 having opposite ends 70,72. The holdingstructure 64 also includes a second plurality 74 of static dissipativeplastic corrugated parallel walls 76 having opposite ends 78,80. Thewalls 76 of the second plurality of walls 74 are perpendicular to thewalls 68 of the first plurality of walls 66. The first and secondpluralities 66,74 of walls are releasably interlockable with one anotherin such a manner as to define a plurality of cavities 82. Each of thecavities 82 is adapted to closely hold one of the sensitive objects.

FIG. 6 shows the interlocking of the parallel walls 68 with the parallelwalls 76. Note in this respect the interlocking of the various holes 67in the sheets with the protrusions 69 in the interlocking sheet with theprotrusions 69 being located in appropriate slits 71.

The sensitive objects holding structure 64 is of a size to fit withinthe bag 62 and when the bag 62 is positioned within the box 12 theholding structure 64 is of a size such that the respective opposite ends70,72,78,80 of the walls 68,76 are closely adjacent the interiors of thepairs 26,28 of parallel opposite pairs of sides of the box 12. Thus,there is a close sandwiching of the bag 62 between the opposite ends70,72,78,80 of the walls 68,76 and the interior of the folding box. Thebag itself is square bottomed and has a flared top. It is easilyextracted, reusable and durable.

FIG. 7 illustrates a plurality of the packages 10 attached to aconventional shipping pad 84 and with the tops of the bag 62 beingfolded over. In the particular embodiment illustrated in FIG. 7 three ofthe packages 10 fit within each of a plurality of larger rectangularboxes 86, each of which is covered with an appropriate corrugated sheet88. The entire assembly is by covered an exterior wrapping sheet 90 andstrapped in place by conventional straps 92. A lift truck can then pickup the entire pad along with, in the embodiment illustrated, forty fiveof the packages 10 in accordance with the present invention fortransport from one location to another, loading on a truck or othershipping vessel, or the like.

It should be noted that the shock absorbing pad structure 38, whichincludes the solid plastic foam 40 covered with the static dissipativeskin 42, forms an important part of the present invention along with theremovable fastening of the pad structure 38 to the folding box 12 andthe fact that the pad structure 38 can be flattened out for shipmentback to the manufacturer. The particular pad structure 38 illustrated ismade of self-skinning polyurethane foam which is available commerciallyfrom a number of suppliers, including BASF, but has not been used forthe purposes of this invention.

INDUSTRIAL APPLICABILITY

The present invention provides a disassembleable and reusable package 10for static, debris and shock sensitive objects such as disc drives. Thepackage 10 can be disassembled after the disc drives which have beenlocated in it have been delivered to a recipient, folded substantiallyflat and inexpensively reshipped to the shipper for reassembly andreuse. Also, the materials of construction are such that they can berecycled if they are damaged. Thus, there is both significant costsaving and a significant environmental improvement attained inaccordance with the present invention.

While the invention has been described in connection with specificembodiments thereof, it will be understood that it is capable of furthermodification, and this application is intended to cover any variations,uses, or adaptations of the invention following, in general, theprinciples of the invention and including such departures from thepresent disclosure as come within known or customary practice in the artto which the invention pertains and as may be applied to the essentialfeatures hereinbefore set forth, and as fall within the scope of theinvention and the limits of the appended claims.

That which is claimed is:
 1. A disassemblable and reusable package forstatic and shock sensitive objects, comprising:a folding box of singlepiece interlocking configuration and made of static dissipativecorrugated plastic, the box having an interlocking bottom, an open topand two pairs of parallel opposite sides having respective upper,central and lower portions; a shock absorbing pad structure adapted tofit against the respective central portions of said sides, the padstructure being made of a solid plastic foam covered with a plasticstatic dissipative skin; fasteners for detachably attaching said padstructure against the respective central portions of said sides; a shockabsorbing plastic bottom pad adapted to fit and to sit inside of saidbox atop its bottom; a bag made of static dissipative plastic andadapted to fit within said box above said shock absorbing bottom pad andto substantially line said box; and a sensitive objects holdingstructure which includes:a first plurality of static dissipativecorrugated plastic parallel walls having opposite ends; and a secondplurality of static dissipative plastic corrugated parallel walls havingopposite ends, the walls of the second plurality being perpendicular tothe walls of the first plurality, the first and second pluralities ofwalls being releasably interlockable with one another in such a manneras to define a plurality of cavities, each cavity being adapted toclosely hold one of said sensitive objects, the sensitive objectsholding structure being of a size to fit within said bag and when saidbag is positioned within said box of a size such that the respectiveopposite ends of said walls are closely adjacent the interiors of thesides of the box.
 2. A package as set forth in claim 1, furtherincluding:an antistatic plastic sheet adapted to fit and to sit atopsaid bottom pad and below said bag.
 3. A package as set forth in claim1, wherein the shock absorbing pad structure is of a self-skinning foamconstruction.